Machines, systems, computer-implemented methods, and computer program products to test and certify oil and gas equipment

ABSTRACT

Embodiments of machines, systems, computer-implemented methods, and computer program products certify oil and gas well equipment. Embodiments identify a selected well equipment device, a device test specification, and testing sequences to be performed by a corresponding testing apparatus. Embodiments select a testing sequence responsive to the selected device. Embodiments control the testing apparatus for the selected testing sequence so that the corresponding testing apparatus performs the sequence responsive to the device test specification. Embodiments generate testing data for the selected testing sequence and link the testing data for the selected testing sequence to the device identifier for the device so that a certificate can be generated. Embodiments generate a certificate for the selected device responsive to the testing sequences having been performed upon the selected device and link the certificate for the selected device to the device identifier so that the certificate can be readily recalled.

RELATED APPLICATIONS

This application claims priority and is related to U.S. ProvisionalPatent Application No. 61/330,248 filed Apr. 30, 2010 titled “Machines,Systems, Computer-Implemented Methods, And Computer Program Products ToTest And Certify Oil And Gas Equipment,” which is incorporated byreference in its entirety herein.

FIELD OF THE INVENTION

The present invention relates to oil and gas production. In moreparticular aspects, the present invention relates to testing andcertification of equipment used in oil and gas production.

BACKGROUND OF THE INVENTION

The production of oil and gas requires specialized well equipment, suchas pipes, valves, joints, and fittings that operate in extremeconditions, including, for example, high pressure, temperature,volatility, and corrosivity. Such conditions promote the rapid wear ofwell equipment and increase the potential for failure. Moreover, whenwell equipment does fail, the impact of the failure is typicallycatastrophic. For example, the failure of well equipment can result inmassive explosions that hurt workers, destroy property, and haltoperations for a significant time—potentially costing millions ofdollars in liabilities, repairs, and lost revenue.

Well equipment particularly susceptible to catastrophic failureincludes, for example, the equipment used in the process of hydraulicfracturing known as “fracing” or “fracking.” The process of fracingcreates or extends fractures in subterranean rock formations by pumpingfluid into the formation at high pressure. For example, fluid-drivenfractures can be formed at the borehole in a drilling operation and then“grown” or extended into the rock formations. The injected fluid maycontain “proppant” particles, such as grains of sand or ceramic, tolodge in the fractures thereby keeping them open. Fracing is used toimprove the rate at which oil and gas can be produced from a reservoir,and fracing is especially useful for extracting oil and gas fromformations having low porosity and permeability, such as shale rock andother formations deep below the earth's surface. The equipment used inhydraulic fracturing for oil and gas wells can include, for example, aslurry blender, high pressure/volume fracturing pumps, high pressuretreating iron, and other pipes, joints, valves, and fittings, which areknown as “frac iron” or, simply, “iron.” For example, frac iron caninclude swivel joints, pup joints, plug valves, check valves and reliefvalves.

To mitigate the likelihood and impact of their failure, frac iron mustbe periodically inspected and recertified according to certainspecifications, which can be provided by, for example, a manufacturer oroperator of the frac iron. Because of the likelihood and impact offailure, inspections can be performed as frequently as every 90 days.Inspections and recertifications typically require several differenttest procedures, which may include, for example, a visual check ofbores, connections, seal surfaces; wall thickness measurements to checkfor erosion or corrosion, for example, using ultrasonic measurement;crack tests, for example, using magnetic particle measurement; andpressure tests, for example, of over 20,000 pounds per square inch(PSI).

Previously known methods to certify frac iron were lengthy andlaborious, often lasting one to three weeks and requiring a human testerto control all testing, to record the results manually, and later toenter the results into a database—costing valuable production capacitydue to downtime.

Also, previously known methods to certify frac iron were susceptible toinconsistencies due to the manually intensive nature of thecertification, such as inconsistent performance of testing operationsand inconsistent adherence to prescribed test specifications. Also, forexample, certification records were created by manual input, introducinghuman error and recording and measurement variances into thecertification records.

Also, previously known methods to certify frac iron were susceptible tooperational inefficiencies. For example, certification records were keptin hard copy, which did not allow on-site operators to readily accesscertifications while in the field, which may be a remote location suchas an offshore rig. Furthermore, certification records and the testresults associated therewith could not be tracked, updated, or reportedon from a central control center.

SUMMARY OF THE INVENTION

Embodiments of the present invention provide systems, methods, andmachines for testing and certifying well equipment that enhance testingmanagement, certification management, field operations management, andasset management. For example, embodiments of the present inventionincrease efficiency in testing and certifying well equipment byproviding a systematic solution to control testing operations. Also,embodiments of the present invention increase efficiency in testing andcertifying well equipment by seamlessly generating, storing, andprocessing testing data immediately upon performance of the testingoperations, allowing a user to view the testing data in real time. Also,embodiments of the present invention increase efficiency in testing andcertifying well equipment by dynamically generating certificates andreports responsive to the testing data according to multiple formats oruser criteria.

Furthermore, well equipment testing according to embodiments of thepresent invention benefit from an increased likelihood of effective andsafe operation because embodiments of the present inventionsystematically ensuring that testers use the proper test specificationsand perform all test operations according to defined test sequences.Also, well equipment tested according to embodiments of the presentinvention benefit from an increased likelihood of effective and safeoperation because embodiments of the present invention systematicallyensure that equipment that fail any test sequence according to definedtesting specifications are scrapped in the system and are unable toproceed in further testing or operation. Also, well equipment testingaccording to embodiments of the present invention benefit from anincreased likelihood of effective and safe operation because operationalcrews can more, readily access certificates, including comprehensivetesting and certification data, on-demand and on-site. Furthermore,manufacturers and suppliers of well equipment can benefit fromembodiments of the present invention by enhancing research anddevelopment efforts with greater knowledge of real-world wear patternsand wear rates for well equipment devices.

In view of the foregoing, applicant has provided a machine to manageperiodic testing and certification of well equipment devices, thetesting and certification being facilitated by a plurality of testingapparatus performing one or more testing operations upon the wellequipment devices. The machine comprises a processor, a non-transitorymemory, an input/output unit to communicate with the plurality oftesting apparatus, a database positioned to match a device identifier toa well equipment device, a test specification, and a plurality oftesting sequences. The machine also comprises a testing module stored inthe memory, the memory being a tangible, non-transitory,computer-readable storage medium, and the testing module being operableby the processor, the testing module comprising a set of instructionsthat, when executed by the processor, cause the testing module toperform operations. The operations of the testing module includeidentifying a selected well equipment device, a device testspecification, and a plurality of testing sequences, the identifyingoperation responsive to receiving a device identifier for the selectedwell equipment device, each testing sequence of the plurality of testingsequences to be performed by a corresponding testing apparatus of theplurality of testing apparatus, each testing sequence defining asequence of testing operations.

The operations of the testing module further include selecting a testingsequence of the plurality of testing sequences, the selecting operationresponsive to the selected well equipment device being positioned sothat the corresponding testing apparatus for the selected testingsequence can perform testing operations upon the selected well equipmentdevice.

The operations of the testing module further include controlling thecorresponding testing apparatus for the selected testing sequence sothat the corresponding testing apparatus performs the sequence oftesting operations upon the selected well equipment device, the sequenceof testing operations being performed responsive to the device testspecification. The operations of the testing module further includegenerating testing data for the selected testing sequence responsive toreceiving output from the corresponding testing apparatus for selectedtesting sequence performing the sequence of testing operations.

The operations of the testing module further include linking the testingdata for the selected testing sequence to the device identifier for theselected well equipment device in the database so that a certificate canbe generated responsive thereto; and

The machine also comprises a certification module stored in the memory,the memory being a tangible, non-transitory, computer-readable storagemedium, and the certification module being operable by the processor,the certification module comprising a set of instructions that, whenexecuted by the processor, cause the certification module to performcertain operations.

The operations of the certification module include identifying aselected well equipment device, a device test specification, and testingdata for a plurality of testing sequences, the identifying operationresponsive to receiving a device identifier for the selected wellequipment device.

The operations of the certification module further include generating acertificate for the selected well equipment device responsive to thetesting data for the plurality of testing sequences, the plurality oftesting sequences having been performed upon the selected well equipmentdevice responsive to the device test specification.

The operations of the certification module further include linking thecertificate for the selected well equipment device to the deviceidentifier for the selected well equipment device in the database sothat the certificate can be readily recalled from the databaseresponsive to the device identifier.

Also in view of the foregoing, applicant has provided a system tocertify oil and gas well equipment. The system comprises a plurality ofdevices to be used in well equipment to define a plurality of wellequipment devices, each well equipment device of the plurality of wellequipment devices having a device identifier associated therewith. Thesystem further comprises a central management server positioned toidentify a device test specification and a plurality of testingsequences for a selected well equipment device responsive to receiving adevice identifier for the selected well equipment device, the devicetest specification and the plurality of testing sequences definingcertification criteria for the well equipment device. The system furthercomprises a plurality of testing apparatus, each testing apparatuspositioned to perform a testing sequence upon the well equipment device,the testing sequence being a sequence of testing operations, thesequence of testing operations being performed responsive to the devicetest specification. The system further comprises a plurality ofcontrollers, each controller positioned to receive commands responsiveto the certification criteria from the central management server and tocontrol the plurality of testing apparatus performing the sequence oftesting operations upon the selected well equipment device responsive tothe device test specification. The system further comprises acertificate generated responsive to the plurality of testing apparatusperforming the plurality of testing sequences upon the well equipmentdevice, the certificate indicating whether selected well equipmentdevice has been tested according to the certification criteria within apre-selected period of time.

Also in view of the foregoing, applicant has also provided acomputer-implemented method to manage periodic testing of a plurality ofwell equipment devices, the testing being facilitated by a plurality oftesting apparatus performing one or more testing operations upon theplurality of well equipment devices. The computer-implemented methodcomprises receiving a device identifier for a selected well equipmentdevice of the plurality of well equipment devices. Thecomputer-implemented method further comprises identifying the selectedwell equipment device, a device test specification, and plurality oftesting sequences, the identifying operation being responsive to thereceiving operation, each testing sequence of the plurality of testingsequences to be performed by a corresponding testing apparatus of theplurality of testing apparatus, each testing sequence defining asequence of testing operations. The computer-implemented method furthercomprises selecting a testing sequence of the plurality of testingsequences to define a selected testing sequence, the selecting operationresponsive to the selected well equipment device being positioned sothat the corresponding testing apparatus for the selected testingsequence can perform testing operations upon the selected well equipmentdevice. The computer-implemented method further comprises calibratingthe corresponding testing apparatus for the selected testing sequenceresponsive to the device test specification. The computer-implementedmethod further comprises controlling the corresponding testing apparatusfor the selected testing sequence so that the corresponding testingapparatus performs the sequence of testing operations upon the selectedwell equipment device, the sequence of testing operations beingperformed responsive to the device test specification. Thecomputer-implemented method further comprises generating testing datafor the selected testing sequence responsive to receiving output fromthe corresponding testing apparatus for selected testing sequenceperforming the sequence of testing operations. The computer-implementedmethod further comprises linking the testing data for the selectedtesting sequence to the device identifier for the selected wellequipment device in a database so that a certificate can be generatedresponsive thereto.

Also in view of the foregoing, applicant has also provided a computerprogram product to manage periodic testing of a plurality of wellequipment devices. The computer program product can be stored in amemory, the memory being a tangible, non-transitory, computer-readablestorage medium, and the computer program product being operable by aprocessor. The computer program product comprises a set of instructionsthat, when executed by the processor, cause the testing module toperform certain operations. The operations performed by the computerprogram product includes identifying a selected well equipment device, adevice test specification, and a plurality of testing sequences, theidentifying operation responsive to receiving a device identifier forthe selected well equipment device, each testing sequence of theplurality of testing sequences to be performed by a correspondingtesting apparatus of the plurality of testing apparatus, each testingsequence defining a sequence of testing operations. The operationsperformed by the computer program product further includes selecting atesting sequence of the plurality of testing sequences, the selectingoperation responsive to the selected well equipment device beingpositioned so that the corresponding testing apparatus for the selectedtesting sequence can perform testing operations upon the selected wellequipment device. The operations performed by the computer programproduct further includes controlling the corresponding testing apparatusfor the selected testing sequence so that the corresponding testingapparatus performs the sequence of testing operations upon the selectedwell equipment device, the sequence of testing operations beingperformed responsive to the device test specification. The operationsperformed by the computer program product further includes generatingtesting data for the selected testing sequence responsive to receivingoutput from the corresponding testing apparatus for selected testingsequence performing the sequence of testing operations. The operationsperformed by the computer program product further includes linking thetesting data for the selected testing sequence to the device identifierfor the selected well equipment device in the database so that acertificate can be generated responsive thereto. The operationsperformed by the computer program product further includes identifying aselected well equipment device, a device test specification, and testingdata for a plurality of testing sequences, the identifying operationresponsive to receiving a device identifier for the selected wellequipment device. The operations performed by the computer programproduct further includes generating a certificate for the selected wellequipment device responsive to the testing data for the plurality oftesting sequences, the plurality of testing sequences having beenperformed upon the selected well equipment device responsive to thedevice test specification. The operations performed by the computerprogram product further includes linking the certificate for theselected well equipment device to the device identifier for the selectedwell equipment device in the database so that the certificate can bereadily recalled from the database responsive to the device identifier.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the features and benefits of the invention,as well as others which will become apparent, may be understood in moredetail, a more particular description of the invention brieflysummarized above may be had by reference to the embodiments thereofwhich are illustrated in the appended drawings, which form a part ofthis specification. It is also to be noted, however, that the drawingsillustrate only various embodiments of the invention and are thereforenot to be considered limiting of the invention's scope as it may includeother effective embodiments as well.

FIG. 1 is a schematic diagram illustrating exemplary data flows andinteractions among components of a system to certify well equipmentaccording to an embodiment of the present invention;

FIG. 2 is a schematic illustrating exemplary components and connectionsof a central management server to certify well equipment according to anembodiment of the present invention;

FIG. 3 is a flowchart illustrating exemplary program product logic andcomputer-implemented methods for certifying well equipment according toan embodiment of the present invention;

FIG. 4 is a database diagram illustrating exemplary data structuresaccording to an embodiment of the present invention;

FIG. 5 is an exemplary certificate according to an embodiment of thepresent invention;

FIGS. 6-8 are flowcharts illustrating exemplary process flow accordingto embodiments of the present invention;

FIGS. 9-23 are exemplary testing interface displays according toembodiments of the present invention; and

FIGS. 24-25 are exemplary reporting interface displays according toembodiments of the present invention.

DETAILED DESCRIPTION

The present invention will now be described more fully hereinafter withreference to the accompanying drawings, which illustrate variousembodiments of the invention. This invention, however, may be embodiedin many different forms and should not be construed as limited to theembodiments set forth herein. Rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art. It is tobe fully recognized that the different teachings of the variousembodiments discussed below may be employed separately or in anysuitable combination to produce desired results. The variouscharacteristics mentioned above, as well as other features andcharacteristics described in more detail below, will be readily apparentto those skilled in the art upon reading the following detaileddescription of the various embodiments, and by referring to theaccompanying drawings. In the drawings and description that follow, likeparts are marked throughout the specification and drawings with the samereference numerals, respectively. The prime notation, if used, indicatessimilar elements in alternative embodiments. The drawings are notnecessarily to scale. Certain features of the disclosure may be shownexaggerated in scale or in somewhat schematic form and some details ofconventional elements may not be shown in the interest of clarity andconciseness.

Accordingly, embodiments of the present invention improve safety,effectiveness, and efficiency of operating well equipment by meeting theforegoing objectives to mitigate the likelihood and impact of thefailure of such equipment. In embodiments of the present invention,“well equipment devices” includes the equipment and devices used inhydraulic fracturing for oil and gas wells, i.e. “high pressurehydraulic fracturing flow iron,” “frac iron,” or, simply, “iron.” Fraciron can include, for example, a slurry blender, high pressure/volumefracturing pumps, high pressure treating iron, and other pipes, joints,valves, and fittings. For example, frac iron can include swivel joints,pup joints, plug valves, check valves and relief valves. Furthermore, byway of example, frac iron can include any type of ball injector, crow'sfoot, air chamber, crossover, hose, pipes/piping, hose loop, ballinjector tee body, tee, wye, lateral, ell, check valve, plug valve,wellhead adapter, swivel joint, plug, relief valve, densometer, cross,frac pump, or cement pump. Those skilled in the art will appreciate thatembodiments of the present invention are not limited to uses related toin oil and gas wells, but, rather, embodiments of the present inventionare applicable to processes for testing or certifying any industrialequipment or device, and at any stage in the lifespan of the equipment,including during or after manufacturing and before, during, or after useor ongoing operations.

FIG. 1 illustrates a central management server 100 for performingoperations of a testing module 220 and a certification module 210. Thecentral management server 100 is positioned to be in communication witha plurality of testing apparatus 110. The plurality of testing apparatus110 is capable of performing testing operations on a selected wellequipment device 101. The central management server 100 is positioned tosystematically control the performing of testing operations upon thewell equipment device 101, systematically record and process the resultsof such testing operations, and systematically generate a certificateresponsive to such recording and processing. Embodiments of the presentinvention providing systems, methods, and machines to certify of wellequipment and are further described herein with specific reference tothe drawings.

Central Management Server 100

An embodiment of a central management server 100, as illustrated in FIG.2, can be configured as a computer, a server, or a machine ofdistributed computers or servers that at least include non-transitorymemory 240, program products 210, 220, and 230, a processor orprocessors 251, an input/output device or devices (“I/O”) 252.

I/O 252 connects the central management server 100 to a database 170, atesting interface 150, and one or more testing apparatus 110 (althoughrepresented as one block, those of skill in the art will appreciate thata plurality of testing apparatus 110 may include one or more links tothe I/O) to thereby allow central management server 100 to send andreceive commands and data, I/O 252 can be any I/O including, but notlimited to a network card/controller connected by a PCI (PeripheralComponent Interconnect) bus to the motherboard, or hardware built intothe motherboard of the central management server 100 to connect same tothe forgoing database, interface, and apparatus.

As those of skill in the art will appreciate, I/O 252 can connect thecentral management server 100 with any other compatible machine, server,system, device, or equipment having a suitable physical interface andthat I/O 252 and/or computer program products 210, 220, and 230 onnon-transitory memory 240 may be positioned to understand, convert, ortranslate application or communication protocols of such machines,servers, systems, devices, or equipment irrespective of nativeprotocols. Also, one of skill in the art will understand that I/O 252can include or otherwise incorporate any logical or physical technologynecessary to effect a connection with any of the aforementioned devices,including, for example, hubs, switches, routers, converters, amplifiers,and wireless transceivers. For example, as is further described herein,I/O 252 can also connect the central management server 100 to devicesfor interacting with radio frequency identification (RFID) devices, suchas an RFID reader or interrogator 130 and an RFID writer 140. Thecentral management server 100 can further connect to a remote userinterface 160 for interacting with a remote user 161, as is alsodiscussed further herein. Also, the plurality of testing apparatus 110,RFID reader 130, and the RFID writer 140 may be configured asperipherals to the testing interface 150. Also, there a testingapparatus 110 interface 253, such as a programmable logic controller(PLC), an interface between the I/O 252 and the plurality of testingapparatus 110 to control the plurality of testing apparatus 110.

As can be seen in FIG. 2, the I/O 252 is connected to a processor 251.The processor 251 is the “brains” of the central management server, andas such executes program products 210, 220, and 230 and works inconjunction with the I/O 252 to direct data to the non-transitory memory240 and to send data from the non-transitory memory 240 to the database170, the testing interface 150, and one or more testing apparatus 110.The processor 251 can be any commercially available processor, orplurality of processors, adapted for use in or with the centralmanagement server 100, e.g., Intel® Xeon® multicore processors, Intel®micro-architecture Nehalem, and AMD Opteron™ multicore processors. Asone skilled in the art will appreciate, processor 251 may also includecomponents that allow the central management server 100 to be connectedto a display, as will be understood by those skilled in the art, andkeyboard or other peripherals that would allow a user to directly orindirectly access the processor 251 and non-transitory memory 240.

Non-transitory memory 240 stores computer program products 210, 220, and230 having instructions for execution on the processor 251, and consistsof both non-volatile memory, e.g., hard disks, flash memory, opticaldisks, and the like, and volatile memory, e.g., SRAM, DRAM, and SDRAM asrequired to support embodiments of the instant invention. As one skilledin the art will appreciate, though the non-transitory memory 240 isdepicted on, e.g., a motherboard, of the central management server 100,the non-transitory memory 240 may also be a separate component ordevice, e.g., FLASH memory, connected to the central management server100 through the I/O 252. The non-transitory memory 240 may also storeapplications that various workstations or remote units can access andrun on the central management server 100. For example, a testing user151 may access applications and computer program products stored on thenon-transitory memory 240 and run on the processor 251 using the testinginterface 150. Importantly, non-transitory memory 240 stores the programproducts 210, 220, and 230 of the instant invention. As one skilled inthe art will understand, the program products 210, 220, and 230, alongwith one or more databases/tables/fields/records for data associatedwith the selected well equipment device 101 can be stored either innon-transitory memory 240 or in separate non-transitory memoryassociated, for example, with a storage medium such as database 170,positioned in communication with the central management server 100.

Database 170

As seen in FIG. 1 and FIG. 2, the database 170 is in communication withthe central management server 100. Although the database 170 isillustrated according to an embodiment in which the database 170 isseparate and distinct from the central management server 100, forexample, as a database server, the present invention may also includeany arrangement of the database 170 in communication with the centralmanagement server 100, including the database 170 being incorporatedinto the same computer, server, machine, or system constituting thecentral management server 100, as one physical unit, for example, as anapplication or partition in the central management server 100 or as aninstalled component of the central management server 100 communicatingwith the processor 251 through the use of the I/O and having, forexample, a database memory separate and distinct from memory 240, suchas a hard drive, optical storage, or the like. Database 170, as isunderstood in the art, can include a processor directing data from a businto the database memory, which can be, for example, a hard drive,optical storage or the like, and computer software that providescomputers, including the central management server, access the datatherein.

The database 170 can store therein a data structure or data structuresrelating to the well equipment devices 101 to be tested and all datagenerated during the execution of the testing module 211 andcertification module 210, as is further discussed herein. Inembodiments, database 170 is a relational database positioned to matchdata by using common data found between data sets, the data sets beingorganized according to tables 400, 410, 420, 430, 440, and 450 as seenin FIG. 4. As will be understood by those skilled in the art, FIG. 4illustrates an exemplary set of data structures only, and there may beother unique table structures positioned to relate and match the data inmanners commensurate with the embodiments of the present invention. Datastored in the database 170 may be updated as needed, for example, by auser with administrative access to the database to add new wellequipment devices to the database as they become supported. As isdescribed further herein with relation to the computer program products,database 170 can be positioned to store data in tables relating to theunique device tested 400, parts in a parts library 410, testspecifications in a test specification library 420, test sequences in atest sequence library 430, test data in a test data repository 440, andcertificate data in a certificate data repository 450. And as isdescribed further herein, the database 170 is positioned to match commondata appearing in the foregoing tables.

Testing Apparatus 110

As shown in FIG. 1 and FIG. 2, the plurality of testing apparatus 110are in communication with the central management server 100. Theplurality of testing apparatus 110 perform testing operations under thecontrol of the central management server 110 and provide tools ordevices to gather testing data 440 as shown in FIG. 4, i.e., the datathat serves as the basis for the certification. In embodiments, theplurality of testing apparatus 110 at least includes an ultrasonic wallthickness meter (“UT meter”) and a pressure test pump having atransducer. The plurality of testing apparatus 110 can include any otherdevice or unit capable of being employed either manually or underautomated control by the central management server 100 to interact withthe well equipment device 101. Other testing apparatus 110 can include,for example, digital calipers. A local user may employ embodiments ofthe present invention, for example, by positioning the frac iron to betested 101 in a testing station adapted for the test performed, and bymanually configuring the frac iron 101 to safely and effectivelyinteract with the testing apparatus 110 for the intended test.

Although shown as separate blocks in FIG. 1, the testing interface 150,which can be a personal computer (PC), can be connected to a peripheraltesting apparatus 110 to control or collect data from a testingapparatus 110 connected as a peripheral to an input/output unit of thePC. The combination of the testing apparatus 110 and a PC may bereferred to, collectively, as a testing apparatus 110. PC or testinginterface 150 can connect to a peripheral testing apparatus 110 via anyconnection type known to those in the art, such as a Universal SerialBus connection (USB), and such connection may include analog inputs anddigital inputs, wired and wireless, and including analog-to-digitalconverters and amplifiers for digital inputs.

The plurality of testing apparatus 110 and a PC incorporated with aperipheral testing apparatus 110 can be a mobile unit or units havingremote or wireless connectivity to central management server 100 usingany protocols or standards known in the art, including Wi-Fi, GSM, andWIMAX, for example. Mobile units may also be synchronized with centralmanagement server through periodic wired or wireless connections whenreturning from field use. The PC can be, for example, any suitable PCknown in the art and is preferably a Panasonic® Toughbook® or otherportable, notebook, laptop, or tablet computer preferably designed towithstand vibration, drops, spills, extreme temperature, and other roughhandling and conditions common to industrial use.

The UT meter can be, for example, an Olympus® MG2DL, or any similar UTmeter known in the art. The UT meter can include, for example, featuressuch as B-scan, gain adjust, auto sensitivity optimizations,echo-to-echo, differential mode, hi-low alarm, and live A-scan. The UTmeter can also include a file-based alphanumeric data logger and aninterface program for transferring data bi-directionally to and from aPC. The testing apparatus 110 can include a PC, such as described above,for enabling data and control functions of a peripheral testingapparatus 110 such as a UT meter.

The pressure test pump and transducer can be any suitable pressure testpump known in the art. Preferably, embodiments of the invention employan X45 series model 345 Viatran® test and control pressure sensor, whichcan, for example, operate in the range of 0-100,000 psi with output inthe range of 4-20 mA. As is known in the art, the testing apparatus 110can include a control interface such as a programmable logic controller(PLC) for communication with and control of the pressure test pump andtransducer.

Testing User 151 and Testing Interface 150

As described above, a testing user 151 may employ embodiments of thepresent invention, for example, by positioning the frac iron to betested 101 in a testing station adapted for the test to be performed,and will manually configure the frac iron 101 to safely and effectivelyinteract with the testing apparatus 110 for the intended test. In otherembodiments, the testing user may perform testing operations accordingto instructions provided by the central management server 110 anddisplayed, for example, on the testing interface 150. The testing user151 may provide the means of manually gathering testing data 440 asshown in FIG. 4, i.e., the data that serves as the basis for thecertification. Testing operations, as described above with reference tothe testing apparatus 110, may be systematic, manual, or hybridsystematic/manual. For example, a sequence of testing operations fortesting wall thickness of the frac iron may include systematic testoperations to be performed by a testing apparatus 110, such as a UTmeter, and manual operations to be performed by a testing user 151, suchas using digital calipers to measure wall thickness or other dimensionsof the frac iron, as can be seen in FIGS. 15-16, for example. Likewise,other sequences of testing operations may be fully manual, such as themag particle test discussed further herein.

Also as described above, the testing interface 150 may be a PC, whichmay be any desktop, laptop, notebook, tablet, or portable computer knownto those in the art. As is known the art, the testing interface 150 caninclude any number of peripheral devices to interact with the testinguser 151, including a keyboard, mouse, control stick/joystick, andmemory reader for receiving data input and a display screen, printer,and local storage device for outputting or storing data. Furthermore,embodiments of invention have a testing interface with a touch-sensitivescreen (e.g., using a stylus) for interactive display/input so thatusers can select parts responsive to viewing them on the display of thetesting interface 150 and thereafter performing testing operationsresponsive to the selection, in communication with the testing module210. The testing interface 150 may connect with the central managementserver 100 via any communications interface known to those of skill inthe art, wired or wireless, and is preferably a secure local Intranet orother authenticated and encrypted communications network, including aVPN over the Internet.

Certificate 500

FIG. 5 sets forth an exemplary certificate 500 generated responsive toembodiments of the present invention. The certificate 500 relates todata stored in the database 170, for example, the certificate data 450as shown in FIG. 4. The certificate 500, as is appreciated by thoseskilled in the art, can be a paper document printout or an electronicdocument in a format such as Adobe® Portable Document Format (.PDF),Microsoft® Word (.DOC or .DOCX), or a similar format. The certificate500, for example, can be a paper document printout, as it is the customin drilling and fracing operations for a paper document printout of acertificate to be presented to company personnel when well equipment isbrought on-site in field operations. The company personnel takespossession of the physical document and reviews the testing parametersand testing results documented thereon to verify the quality of theequipment brought on site.

The certificate 500 can reference the well equipment device 101 by aunique device identifier, such as the serial number 501, which canrelate to data stored in database 170 in the device information table400. The certificate 500 can contain a summary indication as to whethercertain test sequences were graded as a “PASS” or a “FAIL” 502. Thegrading operation, for example, can be performed by a certificationmodule 220 computer program product operating on the central managementserver 100. The PASS or FAIL grading 502 can relate to data stored inthe database 170, for example, the certificate data 450 and the testingdata 440 shown in FIG. 4. The certificate 500 can also contain a summaryor other rendering of testing data responsive to testing operationsbeing performed on the well equipment device 101, for example, agraphical representation of a pressure test 503. Graphicalrepresentation 503 can relate to data stored in the database 170 in thecertificate data table 450 and the testing data table 440.

The certificate 500 can also contain a summary indication as to measuredqualities of the selected well equipment device 101 and their relationto the qualities demanded by the test specification. For example,measured wall thickness value 505 appears adjacent to demanded wallthickness value 506. Additionally, drawing 504 shows a graphicalrepresentation of the parameters measured according to the testspecification, as referenced by letter key (e.g., “A,” “B,” and “C”).

In certain embodiments of the present invention, a certificate can bestored in a proprietary data table format so that a lightweightelectronic copy of the certificate, and an “RFID certificate” can bestored directly onto RFID tag 135 attached to the selected wellequipment 101. For example, as understood by those skilled in the art,the RFID certificate can be written to an RFID tag 135 attached to thewell equipment so that the certificate can be readily accessed in thefield using an RFID reader device 130 capable of recognizing theproprietary data table format. The RFID certificate can include allfields available on the paper certificate 500, including deviceidentifier 501, pass or fail grading 502, tabular summary or renderingof test data 503, drawing 504, measured values 505, and demanded values506. The tabular summary or rendering 503 and the drawing 504 can beencoded, for example, using lightweight vector-based primitive formats.Also, RFID certificate will allow new schemes for protecting certificatedata heretofore unavailable for field use, for example, by havingindividual cells in the table that are protected according to useraccess schemes such as read-only, read-write, or no access. For example,the serial number and the certification may be read-only to all; thecertificate data may be read-only to many and read-write to few; andcustom fields may be user-configurable.

Testing Module 210

As is shown in FIG. 2, the testing module 210 may be a computer programproduct stored in the memory 240 on the central management server 100and operable on the processor 251 thereof. Computer program product 210contains instructions that are operable on the processor 251 that causethe testing module 210 and the central management server 100 to performthe operations discussed further herein.

The testing module 210 can interact with the processor to receive ortransmit data, instructions, and other information from or to any of thedevices connected to I/O 252. In embodiments discussed below, thetesting module 210 at least interacts with the testing interface 150,testing apparatus 110, RFID reader 130, and database 170. Althoughtesting interface 150 has been described to be a personal computer (PC),testing interface 150 can also be implemented in whole or in part as auser terminal interface on the central management server 100 itself, orusing a keyboard, display, or media inputs and outputs connecting to theI/O 252. Testing interface 150 can also be a lightweight graphical userinterface (GUI) operable over a web browser and viewable on anybrowser-enabled device, such as a PC, smart phone, or other equipmenthaving a processor and computer functionality. Testing interface 150,for example, can receive user-selected identifiers or otheruser-selected values or parameters from a testing user as will bedescribed in further detail below and can display identifiers, values,parameters, and other specification data, for example, as can be shownwith reference to the selection, input, or display fields 900, 1000,1100-1101, and 1200-1205 in FIGS. 9-12. Other user selection, input, ordisplay fields are also shown elsewhere in FIGS. 13-25, as will beapparent to those having skill in the art.

The testing module 210 can receive a device identifier for a selectedwell equipment device 101, the selected well equipment device being awell equipment device positioned to undergo testing and certification,i.e., in the testing warehouse, on a testing trailer, or otherwisepositioned at a testing station. In the embodiment of the presentinvention, only one well equipment device is tested at any given timeusing any particular testing apparatus 110. It is possible, however,that multiple instances or threads of the testing module 210 can run onthe processor 251 concurrently, with each instance being directed to thetesting of a different piece of well equipment positioned for testing.It is also possible that multiple testing apparatus 110 of the same typemay be employed to perform the same test sequence in simultaneoustesting operations performed on multiple well equipment devices 101.

The testing module 210 can receive a serial number as a deviceidentifier as shown in FIG. 6. The testing module 210 can receive aserial number as a device identifier, for example, by receiving inputfrom the testing interface 150 as entered therein by a testing user 151.The testing module 210 can also receive a device identifier, such as aserial number, from a peripheral device, such as an RFID reader 130, asis discussed further herein.

The testing module 210 can identify the selected well equipment deviceresponsive to the device identifier as shown in and match the selectedwell equipment to: (i) device library information as shown in FIG. 4 attable 400, the device library information including a part number, and(ii) a part library information at table 410 including type, testspecification, and test profile, as shown in FIG. 7. If the testingmodule 210 is unable to identify the foregoing information as shown inFIG. 8 (i.e., the device has not yet been tested), then the testingmodule 210 can prompt the testing user 151 to enter information toidentify the device as shown in FIG. 9. Once the testing module 210 hasmatched the device 101 to a part number, the testing module 210 canmatch the device to a test specification and a test profile as shown inFIG. 4 at tables 420 and 430. The test specification can be criteria towhich the testing operations will be performed, for example, asspecified by the manufacturer or the customer. Test specifications caninclude, for example, a series of benchmark parameters as shown in FIG.5 at 506. Test specifications can also include, for example, a schematicassociated with the series of parameters as shown in FIG. 5 at 504.

The test profile as shown in FIG. 4 at table 430 may be a plurality oftest sequences that are to be performed upon the well equipment device.A test profile may indicate that certain test sequences shall be run oncertain parts, but not on others. For example, test profiles may bedefined by “levels” as set forth by the logical process flows shown inFIGS. 6-9.

Level 1, as set forth in FIG. 6, can include, for example, making aninventory of all iron and entering al serial numbers or parts andspecifications into the system. Then a testing user can visually examineand record any defects, damage, worn bodies, threads, and wing nuts onthe iron. If the visual examine is acceptable, the tester can proceedwith a wall thickness test, as discussed further herein. If the visualexamination is unsuccessful, the user can scrap the iron in thedatabase, mark the part with orange paint, and return or destroy theiron so that it becomes unusable. If the wall thickness is acceptable,the customer can be contacted if the wall thickness is within 5% of theminimum value set forth in the testing specification. If not, thetesting user can proceed to the pressure test. If the pressure test isacceptable, the final inspection to be signed off by leading supervisor.If continued testing is desired, the tester can proceed to Level 2before performing the pressure test.

Level 2, as set forth in FIG. 7, can include, for example, dismantlingand stripping down and discarding all rubber seals and worn or corrodedparts, then cleaning and removing grease from affected parts withsolvent. Also, the testing user can perform a surface preparation incaustic solution tank, de-scale surfaces area to remove dirt scale,rust, and paint, and pressure rinse to remove caustic solution. Thetesting user then performs the visual examination as specified for Level1, and may scrap the part also as specified for Level 1. If proceedingto Level 3 is acceptable, the testing user goes to Level 3 beforeperforming the pressure test. Otherwise, the pressure test can beperformed as specified for Level 1.

Level 3, as set forth in FIG. 8, can include, for example, inspectingthe part to make sure its free from all oil, grease, paint, scale, rust,and all contaminates that might degrade the result of this inspection.The testing user then coats area to be inspected with wet fluorescentbath and puts a yoke on the part to create magnetic field. The user canpass the part for the magnetic particle test if, using a black light tocheck for indications of cracks and rechecking at right angles, the userfinds no indications of cracks. If the magnetic particle test fails, theuser can scrap the iron in the database as set forth for Level 1. Aftercleaning the part and completing the inspection buyoff, the testing usercan reassemble and fit with news seals and any spare parts required.Thereafter the testing user can perform the pressure test as specifiedfor Level 1 and proceed to paint per the customer's specifications oraccording to standardized paint schemes as set forth in FIG. 8. Afterpainting, the supervising leader must sign off on the final inspection.

Test sequences 1300 can include, for example, visual inspection, wallthickness inspection, disassembly/assembly, magnetic (“mag”) particleinspection, pressure test, paint, and final inspection. As shown in FIG.13, test sequences available for the device 101, (i.e., availableaccording to the test profile 430) can be displayed to the testing user151 using the testing interface 150 so that the testing user 151 mayselect one of the available test sequences to be performed.

Test sequences as shown in FIG. 13 may correspond to one of a pluralityof testing apparatus 110. For example, the test sequence “wall thicknessinspection” corresponds to the UT meter testing apparatus 110 and thetest sequence “pressure test” corresponds to the pressure test pump andtransducer. Other test sequences shown in FIG. 13 may correspond tomanual procedures; for example, the test sequence “visual inspection”corresponds only to operations to be performed by the testing user 151.Each test sequence, as shown in table 440 of FIG. 4, corresponds to asequence of testing operations to be performed upon the well equipmentdevice 101.

Once the testing interface 150 displays the plurality of test sequences440 available for the well equipment device, the testing user 151 canselect a test sequence to be performed. The test sequence shouldcorrespond to the testing user positioning the selected well equipmentdevice so that the testing apparatus 110 can perform the testingoperations. For example, if the testing user 151 has selected thepressure test sequence, the testing user must also ensure that theappropriate testing apparatus 110 (e.g., the pressure pump andtransducer) is positioned upon the selected well equipment device sothat the test can be properly performed.

If the testing user 151 has selected the pressure test sequence or thewall thickness inspection sequence, the testing module 210 willcalibrate the testing apparatus 110 as shown in FIG. 14 and FIG. 15. Incertain embodiments, the calibration 1400, 1500 can be performedresponsive to the tolerances as specified in the test specification 420.Calibration can be performed, for example, by shoring a transducer ofthe testing apparatus 110 to return a rated pressure value or a baselinecalibration setting by the manufacturer, as will be understood by thoseskilled in the art. Embodiments of the present invention can receive thebaseline calibration setting returned and configure a calibrationsetting responsive thereto.

According to certain embodiments of the present invention, the testingmodule 210 systematically controls the performance of testing operationsin certain test sequences. For such testing modules having fullsystematic control of performing the testing operations, e.g., thepressure test sequence, the testing user 151 can initiate theperformance of the testing operations to be controlled by the centralmanagement server 100, as shown at control deck 1600 in FIG. 16. Thetesting module 210 can control the corresponding testing apparatus 110for the selected testing sequence so that the corresponding testingapparatus 110 performs the sequence of testing operations upon theselected well equipment device 101. For example, the pressure testsequence can be performed responsive to the pressure criteria set forthin the test specification. As shown in FIG. 17, the pressure testproceeds systematically as shown in test chart 1700 and the test modulecontrols the performance of a pressurization of the selected wellequipment device 101 for a preselected period of time, for example, asspecified in the test specification.

In further embodiments of the present invention, the testing module 210systematically controls the performance of some testing operations andrequires manual performance of other testing operations (“hybridsystematic/manual”). For testing modules having hybrid systematic/manualperformance of testing operations, such as for wall thicknessinspection, the testing user 151 can initiate the performance of thetesting operations to be controlled by the central management server100, and the central management server 100 can control the testingapparatus 110 as discussed above with respect to fully systematictesting. Also, the testing module 210 can prompt the testing user 151with instructions for the testing user 151 to perform testing operationspursuant to the test specification. As shown in FIG. 18 and FIG. 19, thethickness at “Location A” can be measured and input 1800, 1900 either bythe UT Meter or by the testing user 151 manually measuring Location Awith a digital caliper. The testing module 210 transmits the schematicfrom the test specification to the testing interface 150 so that it maybe displayed 1901 to the testing user 151 and instructs the testing user151 how to perform the test operations with respect to the informationset forth in the schematic and test specification.

In further embodiments of the present invention, the testing module 210requires full manual performance of the testing operations for certaintest sequences. For testing modules having full manual performance oftesting operations, such as for the visual inspection sequence, thetesting module 210 can prompt the testing user 151 with instructions forthe testing user 151 to perform testing operations pursuant to the testspecification. As shown in FIGS. 20-21, band information 2000 and paintparameters 2100 can be input by the testing user 151 responsive toinstructions provided by the testing module 210 to the test interface150, the testing module 210 providing such instructions responsive tothe sequence of testing operations and the test specification. As can beseen in FIG. 17, for example, the testing interface 150 can display theschematic 2001 from the test specification to the testing user 151 andinstructs the user how to perform the test operations with respect toinformation set forth in the schematic and the test specification.

Responsive to systematic, manual, or hybrid systematic/manualperformance of the test operation described above, the testing module210 receives testing data either as captured by the testing apparatus110 for the corresponding testing sequence or as captured by the testinguser 151 and entered into the testing interface 150 according tospecific instructions provided by the testing module 210, e.g., atbanding menu 2000. As shown in FIG. 4, the testing data is stored in thetable 440 and linked to the device library 400 for the selected wellequipment device 101. Also as shown in FIG. 4, an exemplary embodimentof the testing data in table 440 can have individual cells for eachtesting sequence (e.g., wall thickness, pressure test, visualinspection, etc.). The testing data in table 440 can be used, as isdiscussed further herein, to generate certification data by execution ofthe certification module 220 on the processor 251.

Additionally, further embodiments of the present invention includecertain test sequences as described in FIGS. 6-9. These test sequences,for example, can include disassembly/assembly, magnetic particle (“magparticle”) inspection, paint, and final inspection. Although anembodiment of the invention includes manual performance of the testoperations for these sequences, each of these test sequences may beimplemented either by systematic, manual, or hybrid systematic/manualperformance of the testing operations. Regardless of whether theperformance of the testing operations are performed systematically ormanually, those skilled in the art will realize that all testingoperations are performed responsive to a command or instruction beingsystematically issued by the testing module 210 when executed on thecentral management server 100. As such, any test operation describedherein as manual can be performed systematically provided there exists atesting apparatus 110 that can receive an instruction from the centralmanagement server 100 to perform the operation. For example, theperformance of test operations using a digital caliper may be performedeither manually or systematically, although an embodiment employs manualperformance of such operations. Those skilled in the art will understandthat it is within the scope of the invention to employ a testingapparatus 110 having a digital caliper, actuator, and an control deviceto systematically perform a wall thickness measurement using a digitalcaliper in addition to the embodiment employing manual performance.Likewise, it will be understood by those in the art that any manualoperation described herein may also be performed systematically underthe architecture of the central management server as set forth in FIG.2.

Certification Module 220

As is shown in FIG. 2, the certification module 220 may be a computerprogram product stored in the non-transitory memory 240 on the centralmanagement server 100 and operable on the processor 251 thereof.Computer program product 220 contains instructions that are operable onthe processor 251 that cause the certification module 220 and thecentral management server 100 to perform the operations discussedfurther herein.

The certification module 220 can interact with the processor to receiveor transmit data, instructions, and other information from or to any ofthe devices connected to I/O 252. In addition both the certificationmodule 220 and the testing module 210 are in communication with theprocessor 251 and the non-transitory memory 240 so that modules can passor return variables between modules according to a shared API or accessglobal variables being stored on the non-transitory memory 240 to ensureinteroperability and open communication between computer programproducts in communication with the processor 251. Likewise, thoseskilled in the art will understand that computer program products 220and 210 are capable of passing, returning, or referencing commonvariables regardless of whether computer program products are executedon the same processor 251, but that a common API will allowinteroperability and open communications. In embodiments discussedbelow, the certification module 220 at least interacts with the testinginterface 150, RFID reader 130, RFID writer 140, and database 170.Although testing interface 150 has been described to be a PC, testinginterface 150 can also be implemented in whole or in part as a userterminal interface on the central management server 100 itself, using akeyboard, display, or media inputs and outputs connecting to the I/O252. The testing interface 150 can also be a lightweight graphical userinterface (GUI) operable over a web browser and viewable on anybrowser-enabled device, such as a PC, smart phone, or other equipmenthaving a processor and computer functionality.

The certification module 220 can receive a device identifier for aselected well equipment device 101. As described above, “well equipmentdevices” includes the equipment and devices used in hydraulic fracturingfor oil and gas wells, i.e. “high pressure hydraulic fracturing flowiron,” “frac iron,” or, simply, “iron.” Frac iron can include, forexample, a slurry blender, high pressure/volume fracturing pumps, highpressure treating iron, and other pipes, joints, valves, and fittings.For example, frac iron can include swivel joints, pup joints, plugvalves, check valves and relief valves. Furthermore, by way of example,frac iron can include any type of ball injector, crow's foot, airchamber, crossover, hose, pipes/piping, hose loop, ball injector teebody, tee, wye, lateral, ell, check valve, plug valve, wellhead adapter,swivel joint, plug, relief valve, densometer, cross, frac pump, orcement pump. The selected well equipment device is a well equipmentdevice that has previously undergone testing, for example, as describedabove with respect to the testing module 210. The certification module220 can receive a device identifier, for example, responsive toreceiving input from the testing interface 150 as entered therein by atesting user 151. The certification module 220 can also receive a deviceidentifier, for example, responsive to receiving input from a remoteuser interface as entered therein by a remote user 161. Furthermore, thecertification module 220 can receive a device identifier from thetesting module 210 responsive to the testing module 210 having completedexecution of the testing operations and the generation and linking ofthe testing data in the database 170. The certification module 220 canidentify a selected well equipment device responsive to the deviceidentifier and generate and link certification data in database 170, forexample, in certification table 450, responsive to the testing data. Forexample, the certification data 450 can include all data as can beentered onto certificate 500 as a summary or other rendering of testingdata responsive to testing operations being performed on the wellequipment device 101, for example, a graphical representation of apressure test 503. The certification module 220 can include logic togenerate charts and data modeling based upon testing data, which is rawdata stored, for example, in table 440. Further examples of summaries orrenderings of raw testing data responsive to the testing operationsappear on the face of certificate 500. As a result of the linkingoperation, the certification data 440 can be readily accessed or queriedaccording to a serial number for a well equipment device.

The certification module 220 can also generate certification data in aformat responsive the proprietary data table format for the exemplaryRFID certificate. For example, certification module 220 may generatecertificate data according to specific standards or protocols employedin the proprietary standard, for example, cell size, packet size, headerlength, payload length, etc. The RFID certificate can be generated sothat it is ready to be stored to the media attached to the wellequipment without further processing. The certification module 220 mayalso include logic for rendering graphics stored as certification data,such as the schematics and charts, into a lightweight graphics formatssuch as vector graphics formats. The RFID certificate, for example, caninclude all fields available on the paper document, including deviceidentifier 501, pass or fail grading 502, tabular summary or renderingof test data 503, drawing 504, measured values 505, and demanded values506. The tabular summary or rendering 503 and the drawing 504 can beencoded in lightweight vector graphics formats, for example.

Reporting Module 230 and Enterprise Resource Planning Interface

As is shown in FIG. 2, the reporting module 230 may be a computerprogram product stored in the non-transitory memory 240 on the centralmanagement server 100 and operable on the processor 251 thereof.Computer program product 230 contains instructions that are operable onthe processor 251 that cause reporting module 230 and the centralmanagement server 100 to perform the operations discussed furtherherein.

The reporting module 230 can interact with the processor 251 to receiveor transmit data, instructions, and other information from or to any ofthe devices connected to I/O 252. In addition, both the reporting module230 and the testing module 210 are in communication with the processor251 and non-transitory memory 240 so that these two modules can pass orreturn variables between each other according to a common applicationprogramming interface (API) or shared global variables being stored onthe non-transitory memory 240, thereby enhancing interoperability andopen communication between the modules. Likewise, those skilled in theart will understand that computer program products 230 and 220 arecapable of passing, returning, or referencing common variablesregardless of whether computer program products are executed on the sameprocessor 251 and that a common API will allow interoperability and opencommunications as described above. In embodiments discussed below, thereporting module 230 at least interacts with the testing module 210,certification module 220, and database 170. Although remote userinterface 160 may be a PC as has been described for testing interface150, remote user interface 160 can also be implemented in whole or inpart as a user terminal interface on the central management server 100itself, using a keyboard, display, or media inputs and outputsconnecting to the I/O 252. Remote user interface 160 can also be alightweight graphical user interface (GUI) operable over a web browserand viewable on any browser-enabled device, such as a PC, smart phone,or other equipment having a processor and computer functionality.

The reporting module 230 can receive a device identifier for a selectedwell equipment device 101, the selected well equipment device being awell equipment device that has previously undergone testing, forexample, as described above with respect to the testing module 210. Thereporting module 230 can receive a device identifier, for example,responsive to receiving input from the testing interface 150 as enteredtherein by a testing user 151. The reporting module 230 can also receivea device identifier from any other module, as discussed above. Inresponse to receiving the device identifier, the reporting module 230can match the device identifier to any desired data in the database 170,for example, testing data in the database at testing data table 440,certification data in the certification data table 450, device librarydata from the device library table 410, and test specification data fromthe specification library 420. The reporting module, responsive to thedevice identifier, can return any of the test specification for theselected well equipment device 101, testing data for a plurality oftesting sequences performed on the selected well equipment device 101,and certificate data for the selected well equipment device 101, forexample, according to the database structure provided in FIG. 4.

The reporting module 230 may also receive an indication or selection ofadditional variables for reporting purposes, for example, a part number,work order number, etc. In the event that the reporting module 230receives an additional variable, the reporting module 230 can or expandor refine the matched data with respect to the additional variable. Forexample, the reporting module 230 may receive a device identifier, awork order number, and the reporting module 230 will return a list ofall certifications, tests, or specifications for that device identifieraccording to the tests performed under the received work order number.On the other hand, a reporting module 230 may receive a deviceidentifier and a part number, and the reporting module 213 will return alist of all certifications, tests, or specifications for either theselected well device 101 or all well devices tested having the selectedthe part number.

Embodiments of the present invention employing the reporting module 230are beneficial in that they transform the task of testing andcertification—once a costly operational hurdle—into a robust data-pointin business and operational management decisions. For example,manufacturers may use embodiments of the reporting module in researchand development to better understand wear patterns and rates inreal-world applications, to build a better product, and to managecustomer relations. As those skilled in the art will appreciate, thereporting module 230 can be a powerful tool in achievingmanagement-level value from systematic testing and certifications, whichprovides a comprehensive and reliable (i.e., consistent) pool of datapertaining to asset management, inventory management, purchasing, riskmanagement, and other business analytics. Exemplary reports generated bythe reporting module 13 are shown in FIGS. 24-25.

Furthermore, embodiments of the present invention can employ an ERP(Enterprise Resource Planning) interface (not pictured) connected to theI/O of the central management server 100 to provide the foregoingbenefits realized by the reporting module, but in a manner that is morefully integrated into enterprise-wide information systems and providinghigh levels of cross-functional integration, network scalability, andreal-time data synchronization. In particular, embodiments of thepresent invention employ an ERP interface for the purposes of invoicingthe testing and certification operations, for example, responsive towork order information entered by a testing user 151 to the testinginterface 150 as shown in FIG. 6.

RFID 130, 135, 140

Furthermore, embodiments of the present invention can achieve some orall of the foregoing objectives by providing a central management server200 that can communicate with one or more well equipment devices 101.For example, the central management server 200 can be in communicationwith the one or more well equipment devices using wireless communicationtechnologies, for example, radio frequency identification (RFID)technologies. The one or more well equipment devices 101 can include anRFID tag 135, and the central management server 200 can communicate withthe RFID tag 135 on the one or more well equipment devices using an RFIDreader 130 in communication with the central management server 200through the I/O 252. In an embodiment, the RFID tag is a UHF Gen-2 RFIDtag that is attached to the frac iron using a clamp designed to besufficiently robust so that the RFID tag is not affected by the harshoperating conditions of the downhole environment.

In an embodiment, the RFID reader 130 and RFID 140 are peripherals tothe testing interface 150, attaching thereto by known connection meansin the art, such as a USB cable or cables. In certain embodiments, theRFID reader and RFID writer may be one unit, such as an RFIDreader/writer device.

The RFID reader 130 can read a device identifier from the RFID tag on aselected well equipment device 101 through radio frequency communicationand transmit the device identifier to the central management server 200.The central management server is positioned to receive the deviceidentifier from the RFID reader 130. Any of the computer programproducts discussed herein, such as the testing module 210, can receive adevice identifier responsive to the central management server 200receiving a device identifier from the RFID reader 130. An embodiment ofa computer-implemented method for using the RFID reader 130 includes thetesting user 151 having a handheld and/or remote RFID reader 130 inphysical proximity to the selected well equipment device 101 and theRFID tag 135 thereon so that the testing user can interrogate the RFIDtag 135 and so that the RFID tag can transmit the device identifier tothe RFID reader 130.

The RFID writer 140 can write an RFID certificate to the RFID tag on aselected well equipment device 101 through radio frequency communicationand transmit the device identifier to the central management server 200.The RFID certificate can have the qualities and properties as describedherein, preferably including at least a serial number. The centralmanagement server is positioned to transmit the RFID certificate or anydata included therein to the RFID writer 140 responsive to any of thecomputer program products discussed herein, such as the certificationmodule 220. An embodiment of a computer-implemented method for using theRFID writer 140 includes the testing user 151 having a handheld orremote RFID writer 140 in physical proximity to the selected wellequipment device 101 and the RFID tag 135 thereon so that the testinguser can establish a communication link with the RFID tag 135 and sothat the RFID writer can transmit and store the RFD certificate or theinformation therein to the RFID tag 135.

This application claims priority and is related to U.S. ProvisionalPatent Application No. 61/330,248 filed Apr. 30, 2010 titled “Machines,Systems, Computer-Implemented Methods, And Computer Program Products ToTest And Certify Oil And Gas Equipment,” which is incorporated byreference in its entirety herein.

The foregoing has broadly outlined certain features, and technicaladvantages of the present invention and a detailed description of theinvention so that embodiments of the invention may be better understoodin light of features and advantages of the invention as describedherein, which form the subject of certain claims of the invention. Itshould be appreciated that the conception and specific embodimentsdisclosed may be readily utilized as a basis for modifying or designingother structures for carrying out the same purposes of the presentinvention. It should also be realized that such equivalent constructionsdo not depart from the invention as set forth in the appended claims.The novel features which are believed to be characteristic of theinvention, both as to its organization and method of operation, togetherwith further advantages are better understood from the description whenconsidered in connection with the accompanying figures. It is to beexpressly understood, however, that such description and figures areprovided for the purpose of illustration and description only and arenot intended as a definition of the limits of the present invention. Forexample, although the example embodiments discussed herein are directedto oil and gas hydraulic fracturing operations, it should bespecifically noted that the systems, machines, methods, and computerprogram products to test and certify well equipment devices may beemployed to carry out similar functions for other equipment or devicesrequiring routine testing and certification, including withoutlimitation, aircraft maintenance and construction, ship maintenance andconstruction, facilities maintenance and construction, and so on.

1. A machine to manage periodic testing and certification of wellequipment devices, the testing and certification being facilitated by aplurality of testing apparatus performing one or more testing operationsupon the well equipment devices, the machine comprising: a processor; anon-transitory memory; an input/output unit to communicate with theplurality of testing apparatus; a database positioned to match a deviceidentifier to a well equipment device, a test specification, and aplurality of testing sequences; a testing module stored in the memory,the memory being a tangible, non-transitory, computer-readable storagemedium, and the testing module being operable by the processor, thetesting module comprising a set of instructions that, when executed bythe processor, cause the testing module to perform the followingoperations: identifying a selected well equipment device, a device testspecification, and a plurality of testing sequences, the identifyingoperation responsive to receiving a device identifier for the selectedwell equipment device, each testing sequence of the plurality of testingsequences to be performed by a corresponding testing apparatus of theplurality of testing apparatus, each testing sequence defining asequence of testing operations, selecting a testing sequence of theplurality of testing sequences, the selecting operation responsive tothe selected well equipment device being positioned so that thecorresponding testing apparatus for the selected testing sequence canperform testing operations upon the selected well equipment device,controlling the corresponding testing apparatus for the selected testingsequence so that the corresponding testing apparatus performs thesequence of testing operations upon the selected well equipment device,the sequence of testing operations being performed responsive to thedevice test specification, generating testing data for the selectedtesting sequence responsive to receiving output from the correspondingtesting apparatus for selected testing sequence performing the sequenceof testing operations, and linking the testing data for the selectedtesting sequence to the device identifier for the selected wellequipment device in the database so that a certificate can be generatedresponsive thereto; and a certification module stored in the memory, thememory being a tangible, non-transitory, computer-readable storagemedium, and the certification module being operable by the processor,the certification module comprising a set of instructions that, whenexecuted by the processor, cause the certification module to perform thefollowing operations: identifying a selected well equipment device, adevice test specification, and testing data for a plurality of testingsequences, the identifying operation responsive to receiving a deviceidentifier for the selected well equipment device, generating acertificate for the selected well equipment device responsive to thetesting data for the plurality of testing sequences, the plurality oftesting sequences having been performed upon the selected well equipmentdevice responsive to the device test specification, and linking thecertificate for the selected well equipment device to the deviceidentifier for the selected well equipment device in the database sothat the certificate can be readily recalled from the databaseresponsive to the device identifier.
 2. A machine as defined in claim 1,wherein the input/output unit is further positioned to communicate witha testing interface, the testing module further performing the followingoperation: calibrating the corresponding testing apparatus for theselected testing sequence responsive to the device test specificationresponsive to receiving a selection of a test sequence from the testinginterface.
 3. A machine as defined in claim 2, the testing modulefurther performing the following operations: delivering to the testinginterface the device test specification and instructions for performingthe sequence of testing operations so that a local user may view thedevice test specification on a graphical display of the testinginterface and so that the local user may perform the sequence of testingoperations upon the selected well equipment device responsive to thedevice test specification; generating testing data for the selectedtesting sequence responsive to receiving user data from the testinginterface, the user data having been input to the testing interfaceresponsive to the user performing the sequence of testing operationsupon the selected well equipment device.
 4. A machine as defined inclaim 1, wherein the input/output unit is further positioned tocommunicate with a remote user interface, the machine furthercomprising: a reporting module stored in the memory, the memory being atangible, non-transitory, computer-readable storage medium, and thereporting module being operable by the processor, the reporting modulecomprising a set of instructions that, when executed by the processor,cause the reporting module to perform the following operations:identifying a selected well equipment device, a device testspecification, testing data for a plurality of testing sequences, and acertificate, the identifying operation responsive to receiving a deviceidentifier for the selected well equipment device from the remote userinterface, delivering to the remote user interface at least one of thetesting data, the device test specification, and the certificateresponsive to the identifying operation.
 5. A machine as defined inclaim 1, wherein: the input/output unit is further positioned tocommunicate with an RFID reader; and the receiving a device identifierfor the selected well equipment device is responsive to interrogating adevice RFID tag using the RFID reader, the device REID tag beingattached to the selected well equipment device and having the deviceidentifier encoded thereon.
 6. A machine as defined in claim 5, whereinthe input/output unit is further positioned to communicate with an RFIDwriter, the certification module further performing the followingoperations: generating an RFID certificate responsive to thecertificate, the RFD) certificate being formatted so that the RPMcertificate is recognizable by a remote interrogation device having anRFID reader; and delivering an RFID certificate to the device RFID tagusing the RFID writer so that the RFID certificate can be readilyaccessed by the remote interrogation device.
 7. A system to certify oiland gas well equipment, the system comprising: a plurality of devices tobe used in well equipment to define a plurality of well equipmentdevices, each well equipment device of the plurality of well equipmentdevices having a device identifier associated therewith; a centralmanagement server positioned to identify a device test specification anda plurality of testing sequences for a selected well equipment deviceresponsive to receiving a device identifier for the selected wellequipment device, the device test specification and the plurality oftesting sequences defining certification criteria for the well equipmentdevice; a plurality of testing apparatus, each testing apparatuspositioned to perform a testing sequence upon the well equipment device,the testing sequence being a sequence of testing operations, thesequence of testing operations being performed responsive to the devicetest specification; a plurality of controllers, each controllerpositioned to receive commands responsive to the certification criteriafrom the central management server and to control the plurality oftesting apparatus performing the sequence of testing operations upon theselected well equipment device responsive to the device testspecification; and a certificate generated responsive to the pluralityof testing apparatus performing the plurality of testing sequences uponthe well equipment device, the certificate indicating whether selectedwell equipment device has been tested according to the certificationcriteria within a pre-selected period of time.
 8. A system as defined inclaim 7, the system further comprising: a plurality of device RFID tags,each device RFID tag of the plurality of device RFID tags being attachedto a well equipment device of the plurality of well equipment devicesand having a device identifier for the well equipment device encodedthereon; and an RFID reader in communication with the central managementserver and the plurality of device RFID tags, wherein the centralmanagement server is positioned to receive the device identifier for awell equipment device having a device RFID tag attached theretoresponsive to the RFID reader interrogating the device RFID tag.
 9. Asystem as defined in claim 8, the system further comprising an RFIDwriter in communication with the central management server and theplurality of device RFID tags, wherein the central management server ispositioned to generate an RFID certificate responsive to the certificateand deliver the RFID certificate to a device RFID tag using the RFIDwriter.
 10. A system as defined in claim 7, the system furthercomprising database positioned to match a device identifier to a wellequipment device, a device test specification, and a plurality oftesting sequences, wherein the central management server identifies adevice test specification and a plurality of testing sequences for aselected well equipment device responsive to matching the deviceidentifier in the database.
 11. A system as defined in claim 7, thesystem further comprising a testing interface in communication with thecentral management server, wherein: each testing apparatus of theplurality of testing apparatus is positioned to perform a testingsequence responsive to receiving a selection of the testing sequencefrom the testing interface; and the certificate is also generatedresponsive to user data received from the testing interface, the userdata having been input to the testing interface responsive to the userperforming the sequence of testing operations upon the selected wellequipment device responsive to the device test specification.
 12. Acomputer-implemented method to manage periodic testing of a plurality ofwell equipment devices, the testing being facilitated by a plurality oftesting apparatus performing one or more testing operations upon theplurality of well equipment devices, the computer-implemented methodcomprising the following operations: receiving a device identifier for aselected well equipment device of the plurality of well equipmentdevices; identifying the selected well equipment device, a device testspecification, and plurality of testing sequences, the identifyingoperation being responsive to the receiving operation, each testingsequence of the plurality of testing sequences to be performed by acorresponding testing apparatus of the plurality of testing apparatus,each testing sequence defining a sequence of testing operations;selecting a testing sequence of the plurality of testing sequences todefine a selected testing sequence, the selecting operation responsiveto the selected well equipment device being positioned so that thecorresponding testing apparatus for the selected testing sequence canperform testing operations upon the selected well equipment device;calibrating the corresponding testing apparatus for the selected testingsequence responsive to the device test specification; controlling thecorresponding testing apparatus for the selected testing sequence sothat the corresponding testing apparatus performs the sequence oftesting operations upon the selected well equipment device, the sequenceof testing operations being performed responsive to the device testspecification; generating testing data for the selected testing sequenceresponsive to receiving output from the corresponding testing apparatusfor selected testing sequence performing the sequence of testingoperations; and linking the testing data for the selected testingsequence to the device identifier for the selected well equipment devicein a database so that a certificate can be generated responsive thereto.13. A computer-implemented method as defined in claim 12 wherein theselecting operation is responsive to receiving a selection of the testsequence from a testing interface.
 14. A computer-implemented method asdefined in claim 12, further performing the following operation:calibrating the corresponding testing apparatus for the selected testingsequence responsive to the device test specification responsive toreceiving a selection of a test sequence from the testing interface. 15.The computer-implemented method as defined in claim 13, thecomputer-implemented method further comprising the following operations:delivering to the testing interface the device test specification andinstructions for performing the sequence of testing operations so that alocal user may view the device test specification on a graphical displayof the testing interface and so that the local user may perform thesequence of testing operations upon the selected well equipment deviceresponsive to the device test specification; generating testing data forthe selected testing sequence responsive to receiving user data from thetesting interface, the user data having been input to the testinginterface responsive to the user performing the sequence of testingoperations upon the selected well equipment device.
 16. Acomputer-implemented method as defined in claim 12 wherein receiving adevice identifier for the selected well equipment device is responsiveto interrogating a device RFID tag using a RFID reader, the device RFIDtag being attached to the selected well equipment device and having thedevice identifier encoded thereon.
 17. A computer-implemented method tomanage periodic certification of a plurality of well equipment devices,the certification based upon testing data generated responsive to aplurality of testing apparatus performing one or more testing operationsupon the plurality of well equipment devices, the computer-implementedmethod comprising the following operations: identifying a selected wellequipment device, a device test specification, and testing data for aplurality of testing sequences, the identifying operation responsive toreceiving a device identifier for the selected well equipment device;generating a certificate for the selected well equipment deviceresponsive to the testing data for the plurality of testing sequences,the plurality of testing sequences having been performed upon theselected well equipment device responsive to the device testspecification; and linking the certificate for the selected wellequipment device to the device identifier for the selected wellequipment device in a database so that the certificate can be readilyrecalled from the database responsive to the device identifier.
 18. Acomputer-implemented method as defined in claim 16, thecomputer-implemented method further comprising the following operations:delivering an RFID certificate to a device RFID tag using an RFID writerso that the RFID certificate can be readily accessed by the remoteinterrogation device, the device RFID tag being attached to the selectedwell equipment device and having the device identifier encoded thereon.19. A computer program product stored in a memory, the memory being atangible, non-transitory, computer-readable storage medium, and thecomputer program product being operable by a processor, the computerprogram product comprising a set of instructions that, when executed bythe processor, cause the testing module to perform the followingoperations: identifying a selected well equipment device, a device testspecification, and a plurality of testing sequences, the identifyingoperation responsive to receiving a device identifier for the selectedwell equipment device, each testing sequence of the plurality of testingsequences to be performed by a corresponding testing apparatus of theplurality of testing apparatus, each testing sequence defining asequence of testing operations; selecting a testing sequence of theplurality of testing sequences, the selecting operation responsive tothe selected well equipment device being positioned so that thecorresponding testing apparatus for the selected testing sequence canperform testing operations upon the selected well equipment device;controlling the corresponding testing apparatus for the selected testingsequence so that the corresponding testing apparatus performs thesequence of testing operations upon the selected well equipment device,the sequence of testing operations being performed responsive to thedevice test specification; generating testing data for the selectedtesting sequence responsive to receiving output from the correspondingtesting apparatus for selected testing sequence performing the sequenceof testing operations; linking the testing data for the selected testingsequence to the device identifier for the selected well equipment devicein the database so that a certificate can be generated responsivethereto; identifying a selected well equipment device, a device testspecification, and testing data for a plurality of testing sequences,the identifying operation responsive to receiving a device identifierfor the selected well equipment device; generating a certificate for theselected well equipment device responsive to the testing data for theplurality of testing sequences, the plurality of testing sequenceshaving been performed upon the selected well equipment device responsiveto the device test specification; and linking the certificate for theselected well equipment device to the device identifier for the selectedwell equipment device in the database so that the certificate can bereadily recalled from the database responsive to the device identifier.